JP2003531096A5 - - Google Patents

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JP2003531096A5
JP2003531096A5 JP2001578364A JP2001578364A JP2003531096A5 JP 2003531096 A5 JP2003531096 A5 JP 2003531096A5 JP 2001578364 A JP2001578364 A JP 2001578364A JP 2001578364 A JP2001578364 A JP 2001578364A JP 2003531096 A5 JP2003531096 A5 JP 2003531096A5
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gypsum
water
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gypsum composition
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【特許請求の範囲】
【請求項1】 以下を備えた方法により製造された硬化石膏組成物であって:
少なくとも、か焼石膏、水、及び、トリメタリン酸塩化合物、500〜3000のリン酸の繰り返し単位を有するポリリン酸アンモニウム、ポリカルボン酸化合物、界面活性剤、及びこれらの組合せからなるグループから選択された強化剤、から形成された混合物を調製し、ここで水の重量比は混合物中に存在するか焼石膏に対して少なくとも3:1であり;
且つ、か焼石膏が硬化石膏の結合基質を形成するために十分な条件下で混合物を維持することを備えた方法により製造されたことを特徴とする硬化石膏組成物。
【請求項2】 前記強化剤がトリメタリン酸ナトリウム、又はトリメタリン酸ナトリウムと1000〜3000の繰り返し単位を有する少なくとも1つのポリリン酸アンモニウムである請求項1の石膏組成物。
【請求項3】 前記ポリカルボン酸化合物が200,000ダルトンから700,000ダルトンの分子量を有するポリアクリレートである請求項1の石膏組成物。
【請求項4】 前記界面活性剤が、アセチレングリコール系界面活性剤、フッ素含有界面活性剤、シリコーン含有界面活性剤、及びこれらの組合せからなるグループから選択された請求項1の石膏組成物。
【請求項5】 前記界面活性剤が、水の表面張力を40dyne/cm又はそれよりも下まで下げる性能を有することを特徴とする請求項1の石膏組成物。
【請求項6】 前記石膏組成物が、ASTM E 1042−92により、少なくとも0.4の騒音減少係数を有する請求項1の石膏組成物。
【請求項7】 前記石膏組成物が、繊維状のマット、結合剤、膨張パーライト、澱粉、補強添加剤、水泡によって形成された気泡、の少なくとも1つからさらに形成された請求項1の石膏組成物。
【請求項8】 前記水の重量比が、混合物を調製するのに用いられるか焼石膏に対して4.5:1〜9:1である請求項1の石膏組成物。
【請求項9】 前記か焼石膏の、少なくとも50重量%がβ−硫酸カルシウム半水化物である請求項1の石膏組成物。
【請求項10】 混合物を形成するのに用いられる前記強化剤の量が、前記か焼石膏の0.01重量%〜5重量%である請求項1の石膏組成物。
【請求項11】 前記強化剤が、トリメタリン酸塩化合物とポリカルボン酸化合物であるか、又は500〜3000の繰り返しリン酸単位を有するポリリン酸アンモニウムとポリカルボン酸化合物である請求項1の石膏組成物。
【請求項12】 前記水の重量比が、混合物を調製するのに用いられるか焼石膏に対して3:1〜12:1である請求項1の石膏組成物。
【請求項13】 前記水の重量比が、混合物を調製するのに用いられるか焼石膏に対して5:1〜8:1である請求項1の石膏組成物。
【請求項14】 硬化石膏組成物の収縮が、最大でも2%である請求項1の石膏組成物。
【請求項15】 請求項1の石膏組成物を含む石膏ボードを備える物品。
【請求項16】 前記石膏組成物の密度よりも密度が大きい第2の石膏ボードをさらに備える請求項15の物品。
【請求項17】 前記第2の石膏ボードが、少なくとも20lb/ftの密度を有し、且つ、前記石膏ボードが20lb/ftより小さい密度を有する請求項16の物品。
【請求項18】 前記第2の石膏ボード上に担持された壁紙を、さらに備える請求項16の物品。
【請求項19】 前記石膏組成物の密度より大きな密度を有する第3の石膏ボードをさらに備える請求項16の物品。
【請求項20】 第2の石膏ボードと第3の石膏ボードの密度よりも小さい密度を有する第2の石膏組成物をさらに備える請求項19の物品。
【請求項21】 硬化石膏組成物の製造方法であって:
少なくとも、か焼石膏、水、及び、トリメタリン酸塩化合物、500〜3000のリン酸の繰り返し単位を有するポリリン酸アンモニウム、ポリカルボン酸化合物、界面活性剤及びこれらの組合せからなるグループから選択された強化剤から形成された混合物を調製し、ここで混合物を調製するのに用いられるか焼石膏に対する水の重量比が、少なくとも3:1であり;
且つ、か焼石膏が硬化石膏の基質を形成するために十分な条件下で混合物を維持することを備えることを特徴とする、硬化石膏組成物の製造方法。
[Claims]
1. A hardened gypsum composition produced by a process comprising:
At least selected from the group consisting of calcined gypsum, water, and trimetaphosphate compounds, ammonium polyphosphate having 500 to 3000 repeating units of phosphoric acid, polycarboxylic acid compounds, surfactants, and combinations thereof Preparing a mixture formed from a toughener, wherein the weight ratio of water is present in the mixture or is at least 3: 1 relative to calcined gypsum;
A hardened gypsum composition characterized in that the calcined gypsum is produced by a method comprising maintaining the mixture under conditions sufficient to form a bonded substrate for hardened gypsum.
2. The gypsum composition of claim 1 wherein the toughening agent is sodium trimetaphosphate or at least one ammonium polyphosphate having sodium trimetaphosphate and 1000 to 3000 repeat units.
3. The gypsum composition of claim 1 wherein the polycarboxylic acid compound is a polyacrylate having a molecular weight of 200,000 daltons to 700,000 daltons.
4. The gypsum composition of claim 1, wherein the surfactant is selected from the group consisting of acetylene glycol surfactants, fluorine-containing surfactants, silicone-containing surfactants, and combinations thereof.
5. The gypsum composition according to claim 1, wherein the surfactant has a capability of lowering the surface tension of water to 40 dyne / cm or lower.
6. The gypsum composition of claim 1, wherein the gypsum composition has a noise reduction factor of at least 0.4 according to ASTM E 1042-92.
7. The gypsum composition of claim 1, wherein the gypsum composition is further formed from at least one of a fibrous mat, a binder, expanded perlite, starch, a reinforcing additive, and bubbles formed by water bubbles. object.
8. The gypsum composition of claim 1, wherein the weight ratio of water is 4.5: 1 to 9: 1 with respect to calcined gypsum used to prepare the mixture.
9. The gypsum composition of claim 1, wherein at least 50% by weight of the calcined gypsum is β-calcium sulfate hemihydrate.
10. The gypsum composition of claim 1, wherein the amount of the toughening agent used to form the mixture is 0.01% to 5% by weight of the calcined gypsum.
11. The gypsum composition according to claim 1, wherein the reinforcing agent is a trimetaphosphate compound and a polycarboxylic acid compound, or an ammonium polyphosphate having a repeating phosphate unit of 500 to 3000 and a polycarboxylic acid compound. object.
12. The gypsum composition of claim 1, wherein the weight ratio of water is 3: 1 to 12: 1 with respect to calcined gypsum used to prepare the mixture.
13. The gypsum composition of claim 1, wherein the weight ratio of water is from 5: 1 to 8: 1 with respect to calcined gypsum used to prepare the mixture.
14. The gypsum composition of claim 1 wherein the shrinkage of the cured gypsum composition is at most 2%.
15. An article comprising a gypsum board comprising the gypsum composition of claim 1.
16. The article of claim 15, further comprising a second gypsum board having a density greater than that of the gypsum composition.
17. The article of claim 16, wherein the second gypsum board has a density of at least 20 lb / ft 3 and the gypsum board has a density less than 20 lb / ft 3 .
18. The article of claim 16, further comprising wallpaper carried on the second gypsum board.
19. The article of claim 16, further comprising a third gypsum board having a density greater than that of the gypsum composition.
20. The article of claim 19, further comprising a second gypsum composition having a density less than that of the second gypsum board and the third gypsum board.
21. A process for producing a hardened gypsum composition comprising:
Reinforcement selected from the group consisting of at least calcined gypsum, water and trimetaphosphate compounds, ammonium polyphosphates having repeating units of 500-3000 phosphoric acid, polycarboxylic acid compounds, surfactants and combinations thereof Preparing a mixture formed from the agent, wherein the weight ratio of water to calcined gypsum used to prepare the mixture is at least 3: 1;
And a method of producing a hardened gypsum composition, comprising maintaining the mixture under conditions sufficient for the calcined gypsum to form a substrate for the hardened gypsum.

取扱いや輸送効率はもちろん、例えば、防音及び/又は断熱特性をも強化するために、硬化石膏基質の一部を、それよりも低密度の材料(例えば膨張パーライトや気泡)に置き換えることによって、多くのこのような石膏含有製品を軽量化する努力が続けられている。しかしながら、石膏含有製品を実質的に軽量化するためのこれまでの努力は、十分満足がいくものとはなっていない。なぜなら、例えば、石膏含有製品の低密度化を達成するのに十分な空隙容量を作るためにかなりの量の泡が利用され得るのであるが、このような製品は例えば防音及び断熱特性の要求レベルにはまだ達しない場合があるからである。その結果、要求される結果をまだ達成していないのに、低密度石膏含有製品の製造が、相対的に高用量で供給される泡剤によって引き起こされ得る不利な効果に影響されやすい場合がしばしばあった。さらに最近、繊維状のか焼石膏から形成された石膏ボードが、米国特許第5,041,333号で開示されている。繊維状のか焼石膏の製造には、長時間を要しコストが高くつく、それゆえ、繊維状のか焼石膏を使用すると石膏ボードが非常に高価になってしまう。   Many by replacing parts of the hardened gypsum matrix with lower density materials (eg expanded perlite or air bubbles), for example to enhance sound and / or thermal insulation properties as well as handling and transport efficiency Efforts to reduce the weight of such gypsum-containing products continue. However, previous efforts to substantially reduce gypsum-containing products have not been fully satisfactory. This is because, for example, a significant amount of foam can be utilized to create a void volume sufficient to achieve a lower density of gypsum-containing products, but such products are, for example, required levels of soundproofing and thermal insulation properties. This is because there may be cases where it is not yet reached. As a result, the production of low-density gypsum-containing products is often susceptible to adverse effects that can be caused by foams supplied at relatively high doses, yet not achieving the required results. there were. More recently, a gypsum board formed from fibrous calcined gypsum is disclosed in US Pat. No. 5,041,333. The production of fibrous calcined gypsum takes a long time and is costly. Therefore, the use of fibrous calcined gypsum makes the gypsum board very expensive.

本発明によれば、硬化石膏組成物は、結合硬化石膏基質の連続相を備えている。基質は、石膏と増加された蒸発水の空隙容量を含む。蒸発水の空隙容量は、連続相中で表され、これは蒸発水の空隙とは別の不連続点、例えば、紙の繊維や軽量フィラーや泡の気泡が組成物中にあるための不連続点を除外する。ある態様においては、基質の蒸発水の空隙容量は、EMVVテストにより少なくとも約69%(例えば、約69%から約97%)である。好ましくは、蒸発水の空隙容量は、EMVVテストにより、約74%から約95%である。例えば、ある場合には、基質の蒸発水の空隙容量は、EMVVテストにより、約79%から約89%である。   According to the present invention, the hardened gypsum composition comprises a continuous phase of bonded hardened gypsum matrix. The substrate contains gypsum and increased void volume of evaporating water. The void volume of the evaporating water is expressed in the continuous phase, which is a discontinuity separate from the void of the evaporating water, for example discontinuities due to the presence of paper fibers, lightweight fillers and foam bubbles in the composition. Exclude points. In some embodiments, the void volume of the substrate evaporative water is at least about 69% (eg, from about 69% to about 97%) by EMVV test. Preferably, the void volume of the evaporating water is about 74% to about 95% according to the EMVV test. For example, in some cases, the void volume of the substrate evaporating water is about 79% to about 89% by EMVV test.

ある態様においては、ポリカルボン酸化合物は、約200,000ダルトンから約700,000ダルトンの分子量を有し、好ましくは約400,000ダルトンから約600,000ダルトン(例えば約500,000ダルトン)の分子量を有する。例としては、この限りではないが、ポリカルボン酸化合物は、ポリアクリル酸塩、ポリメタクリル酸塩、ポリエタクリル酸塩等や、それらの組合せから選択されても良い。ある態様においては、ポリカルボン酸化合物は、ポリアクリル酸塩であり、この場合のポリアクリル酸塩は好ましくは約200,000ダルトンから約700,000ダルトンの分子量を有し、さらに好ましくは約400,000ダルトンから約600,000ダルトンの分子量を有する。例としては、1つの適したポリアクリル酸塩は、ペンシルバニア州、フィラデルフィア、ローム&ハース(Rohm & Haas, Philadelpia, Pennsylvania)市販で入手可能なアクリゾル(ACRYSOL)(商標)644である。   In some embodiments, the polycarboxylic acid compound has a molecular weight of from about 200,000 daltons to about 700,000 daltons, preferably from about 400,000 daltons to about 600,000 daltons (eg, about 500,000 daltons). Has a molecular weight. Examples include, but are not limited to, the polycarboxylic acid compound may be selected from polyacrylates, polymethacrylates, polyethacrylates, and combinations thereof. In some embodiments, the polycarboxylic acid compound is a polyacrylate, wherein the polyacrylate preferably has a molecular weight of about 200,000 daltons to about 700,000 daltons, more preferably about 400 The molecular weight is from about 1,000,000 Daltons to about 600,000 Daltons. By way of example, one suitable polyacrylate is ACRYSOL ™ 644, commercially available from Rohm & Haas, Philadelpia, Pennsylvania, Philadelphia, Pennsylvania.

石膏組成物は、また、この限りではないが、補強添加剤、結合剤(例えばラテックスのようなポリマー)、膨張パーライト、水泡によって形成された気泡、予めゼラチン化された澱粉のような澱粉、又は(例えば本発明の石膏組成物からなる石膏ボード上に)繊維状のマット、のような任意の添加剤を含んでいても良い。これら任意の添加剤の様々な組合せが、硬化石膏組成物中に含まれていても良い。これらの添加剤は、必要に応じて1つ又はそれ以上の強化剤をも含む石膏組成物中に含ませることができる。   The gypsum composition may also include, but are not limited to, reinforcing additives, binders (eg, polymers such as latex), expanded perlite, bubbles formed by water bubbles, starches such as pregelatinized starch, or An optional additive such as a fibrous mat (for example, on a gypsum board comprising the gypsum composition of the present invention) may be included. Various combinations of these optional additives may be included in the hardened gypsum composition. These additives can be included in a gypsum composition that optionally also includes one or more toughening agents.

さらに密度の低減を促進するために、本発明の硬化石膏組成物は、随意、水泡によって形成される気泡を(蒸発水の空隙に対立するものとして)含んでいても良い。特に、水泡は、現行のボード製品におけるような水系か焼石膏の製造中に加えられても良い。いくつかの適した泡剤が本発明の実施に使用可能で、例えば、ペンシルバニア州、アンブラーのGEOスペシャリティケミカル(GEO Specialty Chemicals, Ambler, Pennsylvania)から入手可能なPFM33がある。   In order to further promote density reduction, the cured gypsum composition of the present invention may optionally contain bubbles formed by water bubbles (as opposed to the voids of the evaporating water). In particular, water bubbles may be added during the manufacture of water-based calcined gypsum as in current board products. Several suitable foams can be used in the practice of the present invention, such as PFM33 available from GEO Specialty Chemicals, Ambler, Pennsylvania, Ambler, PA.

ある態様においては、例えば本発明の石膏組成物が防音タイルのような一定の物品に存在すると、防音特性(例えば騒音減少)が望ましくなる。本発明の石膏組成物は、好ましくは、ASTM E 1042−92によって、少なくとも約0.4の騒音減少係数(Noise Reduction Coefficient)を示し、更に好ましくは、騒音減少係数が1.0又は1.0付近を示す。例えば、ある態様においては、本発明の石膏組成物は、少なくとも約0.5の騒音減少係数を証明し、更に好ましくは少なくとも約0.6の騒音減少係数、更にいっそう好ましくは少なくとも約0.7の騒音減少係数、更にいっそう好ましくは少なくとも約0.8の騒音減少係数、そして更にいっそう好ましくは少なくとも約0.9の騒音減少係数を証明している。一般的に、本発明によれば、防音値(例えば、その騒音減少係数によって測定されたようなもの)は、硬化石膏組成物を調製するのに用いられる混合物中のか焼石膏に対する水の比と共に、硬化石膏結合基質中の蒸発水の空隙容量が増加するにつれて、増加する。   In some embodiments, for example, when the gypsum composition of the present invention is present in certain articles such as soundproof tiles, soundproofing properties (eg, noise reduction) are desirable. The gypsum composition of the present invention preferably exhibits a Noise Reduction Coefficient of at least about 0.4 according to ASTM E 1042-92, more preferably a noise reduction factor of 1.0 or 1.0. Indicates the neighborhood. For example, in some embodiments, the gypsum compositions of the present invention demonstrate a noise reduction factor of at least about 0.5, more preferably at least about 0.6, and even more preferably at least about 0.7. A noise reduction factor of at least about 0.8, and even more preferably a noise reduction factor of at least about 0.9. In general, according to the present invention, the soundproofing value (eg, as measured by its noise reduction factor), along with the ratio of water to calcined gypsum in the mixture used to prepare the hardened gypsum composition. It increases as the void volume of the evaporating water in the hardened gypsum-bound substrate increases.

本発明の他の面によれば、本発明の石膏組成物を備えた物品を提供する。例えば、物品は、壁材、ドアの芯、建築用絶縁パネルシステムの部品、防音タイル、断熱材パネル等の形をとり得る。   According to another aspect of the present invention, an article comprising the gypsum composition of the present invention is provided. For example, the articles may take the form of wall materials, door cores, parts of architectural insulation panel systems, soundproof tiles, insulation panels, and the like.

好ましくは、混合物を調製するのに用いられる少なくとも30重量%の非繊維状か焼石膏を有するか焼石膏に対する水の重量比は、少なくとも約3:1であり、更に好ましくは、約3:1から約12:1である。ある態様においては、混合物を調製するのに用いられる少なくとも30重量%の非繊維状か焼石膏を有するか焼石膏に対する水の重量比は、少なくとも約4.5:1から約9:1であるか、又は混合物を調製するのに用いられる少なくとも30重量%の非繊維状か焼石膏を有するか焼石膏に対する水の重量比は、少なくとも約5:1から約8:1である。繊維状と非繊維状のか焼石膏の混合物の様々な比が本発明の実施において用いられても良いことが、認識されるだろう。硬化石膏組成物が70重量%より多い繊維状か焼石膏から形成される場合は、混合物を調製するのに用いられるか焼石膏に対する水の重量比は、少なくとも約4.5:1から約12:1であり、この態様におけるか焼石膏に対する水の重量比は、好ましくは約4.5:1から約9:1であり、更に好ましくは約5:1から約8:1である。   Preferably, the weight ratio of water to calcined gypsum with at least 30% by weight non-fibrous calcined gypsum used to prepare the mixture is at least about 3: 1 and more preferably about 3: 1. To about 12: 1. In some embodiments, the weight ratio of water to calcined gypsum having at least 30% by weight non-fibrous calcined gypsum used to prepare the mixture is at least about 4.5: 1 to about 9: 1. Alternatively, the weight ratio of water to calcined gypsum having at least 30% by weight non-fibrous calcined gypsum used to prepare the mixture is at least about 5: 1 to about 8: 1. It will be appreciated that various ratios of a mixture of fibrous and non-fibrous calcined gypsum may be used in the practice of the present invention. When the hardened gypsum composition is formed from greater than 70% by weight fibrous calcined gypsum, the weight ratio of water to calcined gypsum used to prepare the mixture is at least about 4.5: 1 to about 12 The weight ratio of water to calcined gypsum in this embodiment is preferably from about 4.5: 1 to about 9: 1, more preferably from about 5: 1 to about 8: 1.

各々のサンプルはそれから、300倍の大きさでSEM撮像中に接地を得るために、銀で塗装される。すべてのサンプルは、固体状態後方散乱電子検出器を装備したトプコン(TOPCON)のSM300のSEMで撮像された。画像は、分析される領域が、その蒸発水の空隙を含む硬化石膏基質の連続相のみであるように視覚的に選択され、大きなサイズの不連続点、例えば結合硬化石膏基質の連続相ではない泡の気泡、紙繊維などは除外した。SEM分析は、“定量鉱物学のための効果的なSEMを基礎とした画像分析体系(An Effective SEM-Based Image Analysis System for Quantitative Mineralogy)”、Kona Powder and Particle, No.11(1993)(参照されて本明細書に組み入れられる)にKingらによって記述されたように、そこに記述されたコンピューターソフトウェアを用いて、行われる。画像分析によって、硬化石膏組成物の結合基質での蒸発水の空隙容量が得られる。   Each sample is then painted with silver at 300 times the size to obtain ground during SEM imaging. All samples were imaged with a TOPCON SM300 SEM equipped with a solid state backscattered electron detector. The image is visually selected so that the area to be analyzed is only the continuous phase of the hardened gypsum substrate including its evaporating water voids, not the large size discontinuities, for example the continuous phase of the bonded hardened gypsum substrate Bubble bubbles and paper fibers were excluded. SEM analysis is based on “An Effective SEM-Based Image Analysis System for Quantitative Mineralogy”, Kona Powder and Particle, No. 11 (1993) (see And is incorporated herein by reference) by using the computer software described therein. Image analysis provides the void volume of the evaporating water at the binding substrate of the hardened gypsum composition.

Figure 2003531096
Figure 2003531096

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